Service Manual for Komatsu PC300LL-7L Excavator (CEBM012100) PDF
$32.95
Komatsu Galeo PC300LL-7L HYDRAULIC EXCAVATOR Shop Manual CEBM012100 – PDF DOWNLOAD
SERIAL NUMBERS PC300LL-7L A85001
Description
Komatsu Galeo PC300LL-7L HYDRAULIC EXCAVATOR Shop Manual CEBM012100 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Galeo PC300LL-7L HYDRAULIC EXCAVATOR Shop Manual CEBM012100 – PDF DOWNLOAD
Language : English
Pages :676
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu Galeo PC300LL-7L HYDRAULIC EXCAVATOR Shop Manual CEBM012100 – PDF DOWNLOAD
SERIAL NUMBERS PC300LL-7L A85001
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this
section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu Galeo PC300LL-7L HYDRAULIC EXCAVATOR Shop Manual CEBM012100 – PDF DOWNLOAD
SERIAL NUMBERS PC300LL-7L A85001
MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 5
SAFETY NOTICE 5
FOREWARD 7
GENERAL 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 9
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 17
CONVERSION TABLES 18
UNITS 23
01 GENERAL 25
DIMENSION DRAWINGS 26
DIMENSIONS 26
WORKING RANGES 28
SPECIFICATIONS 30
WEIGHT TABLE 33
POWERED CAB RISER TILT UNIT TARGETS 35
FUEL COOLANT AND LUBRICANTS 36
PC300LL-7L 36
10 STRUCTURE AND FUNCTION 37
ENGINE RELATED PARTS 39
RADIATOR OIL COOLER AFTERCOOLER 40
FINAL DRIVE SYSTEM 42
PC300LL-7L 42
SWING MACHINERY 45
SWING CIRCLE 48
TRACK FRAME RECOIL SPRING 50
PC300LL-7L 50
IDLER 51
TRACK ROLLER 53
TRACK SHOE 54
TRIPLE GROUSER SHOE 56
HYDRAULIC EQUIPMENT 57
HYDRAULIC TANK 59
HYDRAULIC PUMP 60
HPV125 + 125 60
LS VALVE 65
PC VALVE 65
LS(PC)-EPC VALVE 77
VARIABLE VOLUME VALVE 80
CONTROL VALVE 82
MAIN RELIEF VALVE 93
VARIABLE PRESSURE COMPENSATION VALVE 94
CLSS 95
SELF PRESSURE REDUCING VALVE 98
SWING MOTOR101
SUCTION-SAFETY VALVE104
SWING BRAKE105
CENTER SWIVEL JOINT106
PC300LL-7L107
MOTOR OPERATION109
PARKING BRAKE OPERATION111
BRAKE VALVE OPERATION112
TRAVEL JUNCTION VALVE116
TRAVEL PPC SHUTTLE VALVE118
VALVE CONTROL122
WORK EQUIPMENT SWING PPC VALVE123
TRAVEL PPC VALVE127
ATTACHMENT SOLENOID VALVE136
PPC ACCUMULATOR138
BOOM HYDRAULIC DRIFT PREVENTION VALVE139
QUICK RETURN VALVE145
LIFT CHECK VALVE147
HYDRAULIC CYLINDER148
BOOM CYLINDER148
ARM CYLINDER148
BUCKET CYLINDER149
WORK EQUIPMENT150
DIMENSION OF ARM152
DIMENSION OF BUCKET154
AIR CONDITIONER156
PIPING156
ENGINE CONTROL157
FUEL CONTROL DIAL159
GOVERNOR MOTOR160
ENGINE THROTTLE AND PUMP CONTROLLER161
INPUT AND OUTPUT SIGNALS162
ELECTRONIC CONTROL SYSTEM163
TOTAL SYSTEM DIAGRAM164
MULTI MONITOR SYSTEM187
MONITOR PANEL188
MONITOR CONTROL, DISPLAY PORTION /MONITOR PORTION190
MAINTENANCE FUNCTION201
SENSORS206
ENGINE OIL LEVEL SENSOR206
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)206
COOLANT TEMPERATURE SENSOR207
HYDRAULIC OIL TEMPERATURE SENSOR207
FUEL LEVEL SENSOR208
AIR CLEANER CLOGGING SENSOR208
CAB RISER AND RELATED PARTS209
POWER CONTROL210
STRESS TARGETS FOR CAB RISER KIT211
CAB RISER HYDRAULIC SYSTEM212
20 TESTING, ADJUSTING AND TROUBLESHOOTING213
STANDARD VALUE TABLES215
ENGINE RELATED215
CHASSIS RELATED216
SERVICE TOOLS224
ENGINE224
AIR BOOST PRESSURE224
AIR COMPRESSOR BELT TENSION224
BLOW-BY PRESSURE224
COMPRESSION PRESSURE224
ENGINE OIL PRESSURE224
ENGINE RPM224
ENGINE SPEED SENSOR225
EXHAUST GAS COLOR225
FUEL INJECTION TIMING225
VALVE CLEARANCE225
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE226
SWING CIRCLE BEARINGS226
TRACK SHOE TENSION227
SPROCKET228
OIL PRESSURE228
WORK EQUIPMENT, SWING AND TRAVEL228
CONTROL CIRCUIT233
PUMP PC CONTROL CIRCUIT234
PUMP LS CONTROL CIRCUIT237
ATTACHMENT SOLENOID VALVE OUTPUT241
ATTACHMENT PPC VALVE OUTPUT244
WORK EQUIPMENT AND SWING PPC VALVE245
WORK EQUIPMENT, HYDRAULIC DRIFT LOCATIONS245
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT246
BOOM AND BUCKET CYLINDERS246
BOOM LOCK VALVE246
ARM CYLINDER247
PPC VALVE247
OIL LEAKAGE AMOUNT249
BOOM CYLINDER249
ARM CYLINDER249
BUCKET CYLINDER250
SWING MOTOR250
TRAVEL MOTOR250
AIR BLEEDING OF VARIOUS PARTS251
DIODE INSPECTION PROCEDURES253
MULTI-MONITOR PANEL254
MONITOR PANEL FUNCTIONS255
OPERATOR’S MENU AND DISPLAY (OUTLINE)256
TABLE FOR SERVICE AND FAILURE CODE NOS261
SERVICE MENU263
WAY OF SWITCHING TO SERVICE MENU263
TABLE FOR MONITORING ITEMS266
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARTIONS278
PM TUNE SERVICE279
TROUBLESHOOTING (GENERAL)283
POINTS TO REMEMBER WHEN TROUBLESHOOTING284
SEQUENCE OF EVENTS IN TROUBLESHOOTING286
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE287
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT287
HANDLING CONTROL BOX292
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS293
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT294
CHECKS BEFORE TROUBLESHOOTING296
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS297
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO298
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS301
T-ADAPTER TABLE325
TROUBLESHOOTING ELECTRICAL SYSTEM (E MODE)329
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM331
ABNORMALITY RETURNS TO NORMAL BY ITSELF331
USER CODE MEMORY RETENTION FUNCTION331
INFORMATION CONTAINED IN TESTING PROCEDURES332
(E101)334
ABNORMAL DATA IN ERROR HISTORY334
(E112)336
SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION336
(E113)338
SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION338
(E114)340
SHORT OR OPEN IN WINDOW WASHER SYSTEM340
(E115)342
ABNORMAL WINDSHIELD WIPER MOTION342
(E116)344
ABNORMALITY IN PARKING WIPER ARM344
(E201)346
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID346
(E203)348
SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM348
(E204)350
SHORT IN MERGE/DIVIDE SOLENOID350
(E205)352
SHORT IN 2 STAGE RELIEF SOLENOID352
(E206)354
SHORT IN TRAVEL SPEED SHIFT SOLENOID354
(E211)356
OPEN IN TRAVEL INTERLOCKING SOLENOID356
(E213)358
OPEN IN SWING PARKING BRAKE SOLENOID358
(E214)360
OPEN OF MERGE/DIVIDE SOLENOID360
(E215)362
OPEN IN 2 STAGE RELIEF SOLENOID362
(E216)364
OPEN IN TRAVEL SPEED SOLENOID364
(E217)366
ABNORMAL INPUT FOR MODEL CODE366
(E218)368
OPEN IN S-NET SIGNAL368
(E222)370
SHORT IN LS-EPC SOLENOID370
(E223)372
OPEN IN LS-EPC SOLENOID SYSTEM372
(E224)374
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL374
(E225)376
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL376
(E226)378
ABNORMAL PRESSURE SENSOR POWER SUPPLY378
(E227)380
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER380
(E228)382
SHORT IN ATTACHMENT RETURN SWITCHING RELAY382
(NO CODE)384
SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM384
(NO CODE)387
OPEN IN CAB TILT SYSTEM387
(E232)389
SHORT IN PC-EPC SOLENOID389
(E233)391
OPEN IN PC-EPC SOLENOID SYSTEM391
(E238)393
OPEN IN ATTACHMENT RETURN SWITCH RELAY393
(E245)395
SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM395
(E246)397
OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM397
(E256)399
INCORRECT NON-VOLATILE MEMORY DATA399
(E304)401
SHORT IN ENGINE STOP SOLENOID SYSTEM401
(E314)403
OPEN IN ENGINE STOP SOLENOID SYSTEM403
(E306)405
ABNORMAL GOVERNOR POTENTIOMETER SIGNALS405
(E308)407
ABNORMAL FUEL DIAL SIGNALS407
(E315)409
SHORT IN BATTERY RELAY SYSTEM409
(E316)411
STEP OUT IN GOVERNOR MOTOR411
(E317)413
OPEN IN GOVERNOR MOTOR PHASE “A” AND “B”413
(E318)415
SHORT IN GOVERNOR MOTOR PHASE “A” AND “B”415
(E501)417
MODEL SELECTION FUNCTION NOT PROVIDED417
(E502)418
MODEL SELECTING SIGNAL FAULT418
(AA10NX)419
AIR CLEANER CLOG INDICATOR FAILURE419
(AB00KE)420
LOW CHARGING VOLTAGE INDICATED420
(B@BAZG)422
ABNORMAL ENGINE OIL PRESSURE422
(B@BAZK)423
ABNORMAL ENGINE OIL LEVEL423
(B@BCNS)424
ENGINE COOLANT INDICATING OVERHEAT CONDITION424
(B@BCZK)425
ABNORMAL COOLANT LEVEL INDICATION425
(B@HANS)426
HYDRAULIC OIL OVERHEAT INDICATION426
TROUBLESHOOTING MONITOR ELECTRICAL SYSTEM (E MODE)427
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM428
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF428
USER CODE MEMORY RETENTION FUNCTION428
INFORMATION CONTAINED IN TESTING PROCEDURES429
(E-1)431
ENGINE WILL NOT CRANK431
(E-2)433
ENGINE STOPS WHILE IN OPERATION433
(E-3)435
ENGINE SPEED IRREGULAR, OR HUNTING435
(E-4)437
ENGINE DOES NOT SHUT DOWN437
(E-5)439
AUTO DECELERATOR DOES NOT WORK439
(E-6)440
AUTO ENGINE WARM UP DEVICE DOES NOT WORK440
(E-7)441
COLD START PREHEATER DOES NOT WORK441
(E-8)443
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE443
(E-9)445
ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE445
(E-10)447
NO DISPLAY ON MONITOR PANEL447
(E-11)449
PART OF DISPLAY ON MONITOR PANEL IS MISSING449
(E-12)450
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL450
(E-13)451
FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL451
(E-14)453
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY453
(E-15)455
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY455
(E-16)457
FUEL GAUGE DOES NOT DISPLAY CORRECTLY457
(E-17)459
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY459
(E-18)461
WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS461
(E-19)463
WINDSHIELD WIPER DOES NOT WORK463
(E-20)465
ALARM BUZZER CANNOT BE CANCELLED465
(E-21)467
BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR467
(E-22)469
BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR469
(E-23)471
ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR471
(E-24)473
ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR473
(E-25)475
BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR475
(E-26)477
BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR477
(E-27)479
SWING NOT CORRECTLY DISPLAYED ON MONITOR479
(E-28)481
TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR481
(E-29)483
TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR483
(E-30)485
SERVICE NOT CORRECTLY DISPLAYED ON MONITOR485
(E-31)487
AIR CONDITIONER SYSTEM DOES NOT WORK487
(E-32)491
TRAVEL ALARM DOES NOT SOUND491
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H MODE)495
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS497
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE500
(H-1)501
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW501
(H-2)502
ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS502
(H-3)503
NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT503
(H-4)503
ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP503
(H-5)504
AUTO-DECELERATOR DOES NOT WORK504
(H-6)504
FINE CONTROL MODE DOES NOT FUNCTION504
(H-7)505
BOOM MOVES SLOWLY OR LACKS POWER505
(H-8)506
ARM MOVES SLOWLY OR LACKS POWER506
(H-9)507
BUCKET MOVES SLOWLY OR LACKS POWER507
(H-10)508
WORK EQUIPMENT DOES NOT MOVE IN A SINGLE OPERATION508
(H-11)509
WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT509
(H-12)510
WORK EQUIPMENT HAS EXCESSIVE LAG TIME510
(H-13)511
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT511
(H-14)511
ONE-TOUCH POWER MAX SWITCH DOES NOT OPERATE511
(H-15)511
IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY511
(H-16)512
IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY512
(H-17)512
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY512
(H-18)513
MACHINE SWERVES WHEN TRAVELING513
(H-19)514
MACHINE TRAVELS SLOWLY514
(H-20)515
MACHINE CANNOT BE STEERED EASILY OR LACKS POWER515
(H-21)516
TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING516
(H-22)516
TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY)516
(H-23)517
MACHINE DOES NOT SWING517
(H-24)518
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW518
(H-25)519
EXCESSIVE OVERRUN WHEN STOPPING SWING519
(H-26)520
THERE IS A SUDDEN SHOCK WHEN STOPPING SWING520
(H-27)520
ABNORMAL NOISE CAUSED WHEN STOPPING SWING520
(H-28)521
SWING NATURAL DRIFT IS EXCESSIVE521
30 DISASSEMBLY AND ASSEMBLY523
METHOD OF USING MANUAL525
PRECAUTIONS DURING OPERATION527
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK527
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK528
PRECAUTIONS WHEN COMPLETING THE OPERATIONS529
OTHER PRECAUTIONS529
SPECIAL TOOL LIST530
SKETCHES OF SPECIAL TOOLS533
CONNECTOR REPAIR PROCEDURES535
CONTACT TERMINAL REMOVAL (HD30 TYPE)535
STRIPING INSULATION536
CRIMPING CONTACT TERMINAL (HD30 TYPE)537
INSERTION OF CONTACT TERMINAL (HD30 TYPE)538
CONTACT TERMINAL REMOVAL (DT TYPE)539
STRIPING INSULATION540
CRIMPING CONTACT TERMINAL (DT TYPE)541
INSERTION OF CONTACT TERMINAL (DT TYPE)542
ENGINE543
ALTERNATOR543
CYLINDER HEAD543
ENGINE FRONT SEAL543
ENGINE OIL COOLER543
ENGINE REAR SEAL543
FUEL INJECTION PUMP543
NOZZLE HOLDER543
STARTING MOTOR543
THERMOSTAT543
TURBOCHARGER543
WATER PUMP543
RADIATOR544
REMOVAL544
INSTALLATION545
HYDRAULIC OIL COOLER546
REMOVAL546
INSTALLATION547
ENGINE AND HYDRAULIC PUMPS548
REMOVAL548
INSTALLATION552
FINAL DRIVE553
REMOVAL553
INSTALLATION553
DISASSEMBLY554
ASSEMBLY558
TRAVEL MOTOR564
DISASSEMBLY564
ASSEMBLY568
SWING MOTOR578
REMOVAL578
INSTALLATION578
DISASSEMBLY579
ASSEMBLY581
SWING MACHINERY588
REMOVAL588
INSTALLATION588
DISASSEMBLY589
ASSEMBLY592
IDLER AND RECOIL SPRING597
REMOVAL597
INSTALLATION597
IDLER598
RECOIL SPRING602
TRACK ROLLER604
REMOVAL604
INSTALLATION604
DISASSEMBLY605
ASSEMBLY606
SPROCKET609
REMOVAL609
INSTALLATION609
TRACK SHOE610
EXPANSION OF TRACK SHOE610
ASSEMBLY611
SWING CIRCLE612
REMOVAL612
INSTALLATION612
REVOLVING FRAME613
REMOVAL613
INSTALLATION615
CENTER SWIVEL JOINT616
REMOVAL616
INSTALLATION617
DISASSEMBLY618
ASSEMBLY618
HYDRAULIC TANK619
REMOVAL619
INSTALLATION620
CONTROL VALVE621
REMOVAL621
INSTALLATION623
REPLACING PRESSURE COMPENSATION VALVE SEAL624
ASSEMBLY625
HYDRAULIC PUMP626
REMOVAL626
INSTALLATION628
INPUT SHAFT OIL SEAL629
WORK EQUIPMENT PPC VALVE630
ASSEMBLY630
TRAVEL PPC VALVE631
ASSEMBLY631
HYDRAULIC CYLINDER632
DISASSEMBLY632
ASSEMBLY634
WORK EQUIPMENT638
REMOVAL638
INSTALLATION639
AIR CONDITIONER641
REMOVAL641
INSTALLATION644
COUNTERWEIGHT645
REMOVAL645
INSTALLATION645
OPERATOR’S CAB646
REMOVAL646
INSTALLATION648
MONITOR649
REMOVAL649
INSTALLATION649
GOVERNOR PUMP CONTROLLER650
REMOVAL650
INSTALLATION650
90 OTHERS651
ELECTRICAL653
ELECTRICAL DIAGRAM 1/4 (SHEET 1 OF 3) FOLDOUT 1653
ELECTRICAL DIAGRAM 1/4 (SHEET 2 OF 3) FOLDOUT 2655
ELECTRICAL DIAGRAM 1/4 (SHEET 3 OF 3) FOLDOUT 3657
ELECTRICAL DIAGRAM 2/4 (SHEET 1 OF 1) FOLDOUT 4659
ELECTRICAL DIAGRAM 3/4 (SHEET 1 OF 2) FOLDOUT 5661
ELECTRICAL DIAGRAM 3/4 (SHEET 2 OF 2) FOLDOUT 6663
ELECTRICAL DIAGRAM 4/4 (SHEET 1 OF 2) FOLDOUT 7665
ELECTRICAL DIAGRAM 4/4 (SHEET 2 OF 2) FOLDOUT 8667
HYDRAULIC669
HYDRAULIC DIAGRAM (SHEET 1 OF 3) FOLDOUT 9669
HYDRAULIC DIAGRAM (SHEET 2 OF 3) FOLDOUT 10671
HYDRAULIC DIAGRAM (SHEET 3 OF 3) FOLDOUT 11673
IMAGES PREVIEW OF THE MANUAL:
S.M 19/12/24
